Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1679485 Phoenix Contact	INSERT MALE 40POS+1GND CRIMP	0
1873580000 Weidmuller	INSERT FEMALE 24POS+1GND PUSH IN	9
0936010145 Woodhead - Molex	16P + PE FEMALE INSERT 16A 250V/	9
HMN-017-M TE Connectivity AMP Connectors	MODULE MALE 17POS HMN-017-M	156
0936010261 Woodhead - Molex	S-EP INSERT 16P MALE PUSH-IN TER	15
09140044712 HARTING	MODULE FIBER OPTIC SC FEMALE	0
1852820 Phoenix Contact	INSERT FEMALE 8POS SCREW	12
2-1103013-3 TE Connectivity AMP Connectors	INSERT FEMALE 40POS+1GND CRIMP	0
09140083012 HARTING	HAN GIGABIT MODULE MALE CONTACT	0
C14610A0080002 Tuchel / Amphenol	INSERT MALE 8POS CRIMP	53
1601740000 Weidmuller	INSERT FEMALE 64POS+1GND CRIMP	3021
1650580000 Weidmuller	INSERT FEMALE 7POS+1GND CRIMP	103281
09140022703 HARTING	MODULE FEMALE 2POS SOLDER	2
09200102812 HARTING	INSERT FEMALE 10POS+1GND SCREW	0
C146 10A057 801 6 Tuchel / Amphenol	INSERT MALE 57POS+1GND CRIMP	0
HE-016-MS TE Connectivity AMP Connectors	INSERT MALE 16POS CLAMP	86
09322403101 HARTING	HAN 40EEE HMC-F-CRIMP	0
09140253001 HARTING	MODULE MALE 25POS CRIMP	276
T2080172101-000 TE Connectivity AMP Connectors	HQ-017-M	80
1428860000 Weidmuller	MODULE INSERT FOR INDUSTRIAL CON	2448

Heavy Duty Connectors - Inserts, Modules

1. Overview

Heavy duty connectors inserts and modules are specialized electromechanical components designed to establish robust electrical connections in demanding environments. These systems provide modular solutions for power transmission, signal routing, and data communication in industrial and infrastructure applications. Their importance lies in enabling reliable connectivity in harsh conditions involving high currents, extreme temperatures, vibration, and contamination.

2. Major Types & Functional Classification

Type	Functional Features	Application Examples
Modular Insert Systems	Customizable contact arrangements, hot-swappable design	Industrial control cabinets, automated machinery
High-Power Modules	Rated for >100A currents, integrated cooling channels	Electric vehicle charging stations, factory automation
Signal Transmission Inserts	Shielded contacts for <10Gbps data rates	Smart grid monitoring systems, robotics
Hybrid Power-Signal Modules	Combined power and fiber optic transmission	Wind turbine pitch control, mining equipment

3. Structural Composition

Typical construction includes:

Durable thermoplastic or metal housing (IP65-IP69K rating)
Copper alloy contact elements with gold/silver plating
Integrated locking mechanisms (screw, bayonet, or push-pull)
Modular frame supporting mixed contact types
Environmental seals (EPDM or silicone rubber)

4. Key Technical Specifications

Parameter	Importance
Current Rating (10-2000A)	Determines power transmission capacity
Voltage Range (24V-10kV)	Defines insulation requirements
Contact Resistance (<1m )	Impacts energy efficiency and heat generation
Operating Temperature (-40 C to +125 C)	Dictates environmental suitability
Mating Cycles (500-10,000)	Determines service life and reliability

5. Application Fields

Primary industries include:

Industrial Automation: PLC systems, CNC machines
Energy: Wind turbines, solar inverters
Transportation: Rail traction systems, e-mobility charging
Heavy Machinery: Excavators, mining equipment
Marine: Offshore platform systems, shipboard power

6. Leading Manufacturers & Products

Manufacturer	Representative Product
TE Connectivity	DEUTSCH HC Series High-Current Connectors
Amphenol Industrial	MAXdur Hybrid Power/Sig nal Modules
Phoenix Contact	Heavycon Modular Insert Systems
Weidm ller	HA-Modular Hybrid Connection Technology

7. Selection Guidelines

Key considerations:

Calculate maximum current/voltage requirements with safety margins
Assess environmental factors (temperature, vibration, chemicals)
Verify IP rating for ingress protection
Evaluate mating cycle requirements
Check industry-specific certifications (UL, CSA, IEC standards)
Consider modular expandability for future upgrades

8. Industry Trends

Current development trends include:

Miniaturization while maintaining high current capacity
Integration of smart sensing capabilities
Adoption of fiber-optic hybrid transmission
Increased use of corrosion-resistant composite materials
Development of quick-connect systems for reduced downtime

Market growth is driven by electrification in industrial sectors and the rise of renewable energy systems, with a projected CAGR of 6.2% through 2028 (Source: MarketsandMarkets).